DRAFT

GUIDELINES
FOR
USAGE
OF
UNDER GROUND CABLE SYSTEM
OR
OVERHEAD CONDUCTOR SYSTEM

CENTRAL ELECTRICITY AUTHORITY

2018
1. INTRODUCTION

Distribution of electricity involves the transfer of electrical energy from one electric
substation to another electrical substation ( like from 220/33 KV S/S to 33/11 KV S/S
and 33/11 KV S/S to 11/0.4 KV Distribution Transformer S/S etc) through sub-
transmission and distribution lines. These lines may be Overhead lines or Underground
cables. Each of the two types has its merits and demerits.
The choice of Overhead Network or Underground network depends on many factors like
safety requirement, Availability of Right of way, cost , aesthetic look etc. Despite being
expensive, Underground cables have several advantages over OH lines. These are
mostly used where safe clearances for Overhead Network is not available particularly in
densely populated areas. Overhead Network is cheaper, easy to install/upgrade and easy
to maintain.

a. OVERHEAD NETWORK
In overhead power lines, a structure based network is used to transmit electrical energy
from one point to another. It consists of adequate size of conductors , commonly three
conductor in 66 KV , 33 KV or 11 KV lines or four conductor in 11 KV lines or 5 conductor
in LT lines ( 5th conductor for street lighting) for three phase lines and two conductors for
single phase lines suspended through towers or poles and generally comprising of the
items- such as Poles, Conductors, Cross arms, pin insulators, Stay Wires, Stay Rod,
Stay Anchor, Guy Insulator, earthing materials, Guard wire, Barbed wire and Danger
plate etc

The Poles for the electrical network may be a Steel Poles (Tubular Poles, Rolled Steel
Joists and Rails),Concrete Poles (RCCPoles,PCC poles and Pre-Stressed Concrete -
PSC) Pole) of various heights of 9 meters to 13 meters (IS: 5613 (Part 1, 2, 3) depending
on site location, minimum safety clearance and Voltage (230Volts, 415Volts, 11KV and
33KV etc) of the overhead network system. Along with these poles, Rail poles, which
have more strength then other poles, are generally used in overhead network along
and across the Road, Public Places, Residential areas, River crossing etc.

Sometimes, for supporting different voltages on the same poles and to maintain the
adequate clearance between the different lines of different voltage levels, poles with
higher heights are used, and in such cases, guard wires are also provided to prevent
accidental over charging of lines of lower voltage system due to conductor snapping etc.

The conductors for the overhead network can be a bare conductor or an insulated
conductor (ABC) depending on the requirement. It is an important component of
overhead electrical transmission and distribution systems. The choice of conductor
depends on the power carrying capacity, cost, growth of the load, and reliability &
efficiency. While selecting an ideal conductor, some of the following features such as -i)
maximum electrical & thermal capacity and cost effectiveness etc are considered.

As per CEA (Technical Standards for construction of Electrical Plants and Electric Lines)
regulations 2010, as amended upto date, adequate capacity AAC (All Aluminium
Conductor), AAAC (All Aluminum Alloy Conductor), ACSR (Aluminum Conductor Steel
Reinforced), ACAR (Aluminum Conductor, Aluminum Reinforce) or any new technology
higher current carrying conductors (AL-59, HLTS etc) may be used in sub –transmission
and Distribution system. Since, the insulations between the conductors is provided by air,
overhead power lines are generally the lowest-cost method of power transmission for
large quantities of electric energy from one point to another.

In addition to above types of bare conductors, Insulated conductors (Aerial Bunched

cables) may also be used in Overhead network system. The use of Aerial Bunched
Cables (ABC) is a good concept for overhead power LT distribution where the electrical
clearance is not available or area identified as theft prone. When compared with the
overhead distribution system with conventional bare conductors, ABC provides higher
safety and reliability and system economy by reducing theft. This system is ideal for
rural distribution and especially suitable for installation in difficult terrains such as hilly
areas, forest areas, coastal areas etc. Aerial Bunched Cables is also considered to be
the best choice for power distribution in congested urban areas with narrow lanes and
by-lanes.

Some other advantages of use of ABC are-

 ABC provide safety to human life when used in congested area and narrow
lane areas.
  ABC provides flexibility to use multiple circuits of different voltages strung on
the same set of poles.
 ABC provides better adaptability to run concurrently with other overhead
system with bare conductor and also with communication lines without any
interference.
 ABC provides insulation resistance to earth in all seasons and negligible
leakage of currents and thereby, the reducing losses due to leakage.
 ABC is unaffected by atmosphere pollution.
 ABC, also eliminates the theft of energy as it can not be tapped i.e. it prevents
the use of illegal hooks etc. on LT lines in the theft prone areas and helps to
improve the AT&C losses of the system.

b. UNDERGROUND NETWORK

In Under Ground cable system, the power is transferred from one point to another through
underground cables laid in the ground in place of overhead lines on poles/ towers. As
these cables are not exposed to the air/ atmosphere, they are less susceptible to outages
due to various atmospheric conditions like high wind, storm, thunder storms, heavy snow
or ice storms etc. As these cables are not visible on ground, these provide an
aesthetic look to the area as compared to OH lines. However, the U/G cables are more
costly and have to be laid in the proper tranches and also have more restoration time in
case of any fault as compared to OH lines.

While selecting the cables to be used, some of the parameters such as Current carrying
capacity, Voltage drop and short circuit rating are important factors to be considered to
arrive at economical and optimum size of cable.
 The cable generally comprises of the conductor, insulation material, bedding, beading/
armoring, and outer sheath etc. Although, the armoring and outer sheath takes care of
the physical safety of cable , adequate care has to be taken by cable manufactures during
manufacturing of the cable.

Normally the lifespan of a cable is about 40 to 50 years. But over the time, the insulation
of cable may get damaged or weakened due to ageing. Wrong handling of cables, such
as damages due to wrong handling/bending or laying of cable also weakens the
insulation of the cables. Normally, some of common cable faults are:

i. a short circuit between two conductor due to failure of insulation between the
conductors

ii. a earth fault, i.e., fault between conductor and ground due to failure of outer
insulation sheath

iii. an open circuit fault, caused due to break in conductor etc.

The choice to use overhead line (OHL) or underground cable (UGC) must be made
keeping in view the safety, reliability and operational constraints. The choice between
OHL and UGC is driven by technical, environmental and economic considerations.

2. COMPARISON OF UG SYSTEM AND OH SYSTEM - FEASIBILITY ANALYSIS

Feasibility study of Overhead and Underground line on various points is classified below:

i. COST OF INSTALLATION
Underground network installation is more expensive than OH lines , since the cost
of cables include cable charges along with road restoration charges which make
the per unit coat of UG cabling system several times greater than overhead
system.

ii. FAULT LOCATION IDENTIFICATION & REPAIRING TIME

The identification of fault finding and repairing on overhead wire is easy as
compared to UG cables, as UG cables are buried in the ground and it requires
specialized techniques to find out the fault location as compared to OH lines. Some
time, it may take several days or weeks to find and repair the fault in underground
system.

iii. COST OF REPAIR A FAULT

In underground cables, when a fault occurs, the cost of finding its location,
trenching, cable splicing, and re-embedment is sometimes 5 to 10 times more
expensive than repairing a fault in an overhead line where the conductors are
visible, readily accessible and easier to repair.
 iv. LINE OUTAGE DURATIONS
As extended repair time is required in underground system, services to customers
may be disrupted for a long time in UG system. However, the time duration of
customer outages can be reduced by using additional feeders with Ring Main Units
(RMUs) in UG system which involves much more cost as compared to OH system.

v. LINE MODIFICATIONS
Overhead power lines are easily tapped, rerouted or modified to serve customers;
while underground lines are more difficult to modify after the cables have been laid.
Such modifications to underground power lines are more expensive because of the
inability to readily access lines or relocate sections of lines.

vi. EFFECT FROM WEATHER CONDITIONS

Overhead Lines are more prone to damage from severe weather conditions
(mainly lightning, hurricanes/cyclones/typhoons, tornados, other winds, and
freezing) than Underground Network.

vii. RANGE OF ELECTROMAGNETIC FIELDS (EMF) EMISSION

The electric current in the conductor produces a magnetic field around it. However,
the closer grouping of underground power cables reduces the resultant external
magnetic field and hence provides less magnetic effect as compared to OH line
conductors. Further to reduce the magnetic effect in cables, a shielding is also
provided over the cables which further reduces the magnetic effect in surrounding
areas.

viii. SPACE REQUIREMENT

Underground cables do not need physical ground space as these are laid under
the ground in the dedicated tranches whereas an overhead line requires a corridor
on ground along with surrounding clearance strip permanently clear for safety,
maintenance and repair.

ix. HAZARD TO WILDLIFE

Underground cables generally pose no hazard to wildlife as compared to overhead
network, as live wires are not exposed to be touched.

x. ILLEGAL CONNECTION/THEFT OF POWER /PILFERAGE

In underground cabling system, it is generally impossible to have illegal connection
by tapping the conductor for theft of power. These are also less prone to sabotage,
and damage from armed conflict.

xi. AESTHETICS
As UG cables are not visible from outside, these provide a clean and aesthetic view
of the city /town where UG cables are laid. The above space may be used for any
 other purposes like making of roads, providing green environment/trees on
sidewalks etc having environmental benefits and increase of property values etc.

xii. FLEXIBILITY TO INCREASE LINE CAPACITY

Overhead lines can easily be upgraded/ augmented by modifying line clearances
and power poles to carry more power while underground cables cannot be up-rated
and must be supplemented by laying another cables or to be replaced to increase
the capacity.

xiii. LINE LIFE

Insulation deterioration takes place in underground cables much faster because of
various loading cycles during their lifetimes as compared to OH conductor which
do not have any insulation layering. As time passes, the cables insulation weakens,
which increases the potential for a line fault.

xiv. SAFETY
As OH conductor are exposed in air, a minimum safety clearance is required for
the overhead line from any surrounding like surrounding building /trees etc. which
may not be available in densely populated areas, while underground cables do not
require such clearances. Also, the snapping of the overhead conductors in densely
populated areas poses serious safety hazard. Hence, UG cables are preferred in
the densely populated areas.

3. COST ANALYSIS
As discussed above, the estimated cost of the UG cabling system is about 3-4 times than the
equivalent OH system ( like the Est cost of 11 KV OH S/C line with Dog conductor is around
Rs 5-6 Lakh/ km while the Est cost of 1 km of 3 x300 sq mm 11 KV cabling system would be
around Rs 20 Lakh/km). The tentative unit costs of 11 KV OH lines and UG cabling system
are given in Annex. These are only the suggestive figures and the actual costs may vary frm
utility to utility based on there technical requirement / schedule rates etc.

Following is the cost comparison for installation of one kilometer of underground and
Overhead lines:

Voltage Tentative Estimated Cost Per km (lacs)

S No.
Level OH UG ABC
1 LT 3.5 13 8
1 11 kV 5.0 20 13.5
3 33 kV 12.0 35
5 66 kV 45.0 80

The above cost may vary depending upon road restoration cost for installation of the
underground cables/ overhead poles. The cost is much higher for installation of underground
cables depending on the nature of the road surface to be disturbed and area of installation
(Metropolitan/Rural area etc).
4. RECOMMENDATION
It may be seen that both overhead & underground network have their own advantage and
disadvantage over each other and also have virtually no cost comparison for cost benefit
analysis. As a sub-transmission and distribution line cover the landscape and population
structure within the city/town/village throughout its length, the choice between OH and U/G
cabling system has be taken based on safety, esthetic look, clearance available, rules and
regulations in force and other factors. The sub transmission and distribution lines may also
be a mix of both as per actual site conditions. Underground power distribution system is an
expensive choice but is mandatory to supply electricity in highly populated areas.
 Annex
(NOTE: These are the typical examples of cost estimate of OH line/UG cables.The
actual estimates of the Discoms may differ depending upon their schedules cost
estimates as approved by their competent Authorities in Discoms)

TYPICAL COST ESTIMATE FOR 1KM 11 KV (SINGLE CIRCUIT) OVERHEAD HT LINE

WITH
DOG CONDUCTOR ON STEEL TUBULAR POLE
S. No Particulars Unit Qty Rate Amount(Rs)
1 ST Pole 9 Mtr. No. 25 2904 72600
X-arm M.S. Angle
2 No. 25 597 14925
65x65x6mm V Type
Cross arms holding
3 No. 25 57 1425
clamps
11 kV Pin insulators with
4 Nos 75 67 5025
GI Pins(320CD)
5 45 kN disc insulators Nos 6 533 3198
F-bracket for fitting top
6 No. 25 228 5700
insulator
7 ACSR Dog conductor Km 3.09 59579 184099
Jointing sleeve for
8 No. 3 171 513
ACSR DOG
9 Danger Plate Nos 25 155 3875
10 Barbed wire Kg. 8 68 544
11 Stay Set Complete No. 8 1140 9120
Sectional D/P on Steel
12 No. 1 45593 45593
Tubular Pole
Concreting of supports
13 No. 25 969 24225
ST Pole
Stone pad
14 No. 25 182 4550
300x300x75mm
15 Earthing complete No. 6 570 3420
Material Cost in Rs 378812
Misc. Items (Like Nut &
Bolts,Clamps,Binding

0.50% 1894
Wire,Aluminium Tape
etc) @ 0.5 % of the
material cost
Contingency @3% of
3% 11365
Material Cost
Total Material Cost
392090
(Part-I)
TYPICAL COST ESTIMATE FOR 1KM 11 KV (SINGLE CIRCUIT) OVERHEAD HT LINE
WITH
DOG CONDUCTOR ON STEEL TUBULAR POLE
S. No Particulars Unit Qty Rate Amount(Rs)
*Labour Cost for
execution of the
Scheme, Overhead
charges including
Transportation,
14% 54893
Establishment &
Supervision Charges for
Erection, Testing &
Commissioning
(Part-II)
Total Cost (Part-I+Part-
447082
II)
Say in Rs. Lakhs 4.47

TYPICAL COST ESTIMATE FOR 1 KM HT OVERHEAD LINE WITH 11KV ABC CABLE
WITH SPAN 30 METERS
Sl.No Particulars Unit Qty Rate Amount(Rs)
1 PCC Poles 11 M No. 35 5465 191275
2 ABC Cable 3CX150+150 mm2 Kms 1.02 760013 775213.26
Clamp Suspension LT ABC
3 3X120-150 EA 35 244 8540
SQMM
EYE HOOK ANCHOR/
4 EA 35 118 4130
SUSPENSION CLAMP 300MM
Anchor HT ABC 3CX120 TO 150
5 EA 10 349 3490
SQMM
EYE HOOK ANCHOR/
6 EA 10 118 1180
SUSPENSION CLAMP 300MM
7 Stay Set Complete No 10 1140 11400
8 Stay Wire GI,7/8 SWG kg 100 65 6500
Full clamp assembly (alongwith
9 No 10 57 570
Nuts,Bolts and Washers) for stay
10 Egg insulators No 10 13 130
11 Barbed wire kg 35 68 2380
Pipe earth G.I. 40MMX2.5/3 M
12 'B' EA 40 706 28240
CLASS
13 PIPE HDPE SIZE 25 MM EA 120 22 2640
TYPICAL COST ESTIMATE FOR 1 KM HT OVERHEAD LINE WITH 11KV ABC CABLE
WITH SPAN 30 METERS
14 WIRE STAY GI 7/10 SWG KG 400 65 26000
LUG AL Crimping 70 SQMM
15 XLPE EA 160 20 3200
SINGLE HOLE
GI Strip 25x6 mm , 9 meter for
16 No 7 570 3990
earthing
Phase plate for each phase set
17 Set 35 57 1995
of 3 (on each H-Pole & 4-Pole)
18 Danger Plate No 35 155 5425
19 Number Plate No 35 70 2450
JT. KIT O/D HT ABC
20 3CX150+1CX150 EA 12 1797 21564
HS ONE
COVER INSULATION
21 EA 9 2251 20259
REOPENABLE ON INSULATOR
22 CHANNEL MS SIZE 75X40MM KG 89 65 5785
23 ANGLE MS SIZE 50X50X6MM KG 41 33 1353
24 FLAT GI SIZE 50X6MM KG 15 123 1845
Total Material Cost(Part-I) 1129554
*Labour Cost for execution of the
Scheme,Overhead charges
including Transportation,
Establishment & Supervision 14% 163651
Charges for Erection, Testing &
Commissioning @14% of Total
Material Cost(Part-II)
Total cost in Rs.(Part-I+Part-II) 1332688
Say(Rs. In Lakhs) 13.33

TYPICAL COST ESTIMATE FOR 1 KM 11KV UNDERGROUND XLPE CABLE (3CX300

SQ.MM. )
Sl.
Particulars Unit Qty. RATE Amount
No.
HT 11 kV 3CX300
1 M 1000 1137 1137000
sq.mm XLPE cable
11kV outdoor Joint Kit
2 No. 2 2471 4942
3X300 Sq. mm.
 TYPICAL COST ESTIMATE FOR 1 KM 11KV UNDERGROUND XLPE CABLE (3CX300
SQ.MM. )
Sl.
Particulars Unit Qty. RATE Amount
No.
11 kV Straigth Through
3 No. 3 5846 17538
Joint Kit 3X300 Sq.mm.
RCC Hume
4 Nos. 50 355 17750
Pipe,150MMX2M
Collar RCC Hume Pipe
5 Nos. 30 55 1650
150MM
Route and Joint
6 No. 30 130 3900
indicating stone
RCC cable cover( 2 feet
7 No. 1666 243 404838
long)
8 Sand No. 250 388 97000
Pipe earth G.I.
9 EA 2 706 1412
40MMX2.5/3 M 'B' Class
10 Pipe HDPE Size 25MM M 6 22 132
LUG AL Crimping 70
11 SQMM XLPE Single EA 8 20 160
HOLE
12 FLAT GI Size 25x6 MM KG 7 78 546
Cleat HDPE for Cable
13 KG 4 763 3052
Support
Pipe G.I. 100MM DIA 'B'
14 M 6 716 4296
CLASS
15 FLAT GI Size 50x6 MM KG 10 123 1230
Channel MS Sixe
16 EA 60 65 3900
75x40MM
Material Cost 1699346
Misc Material like nuts &
Bolts, Lugs etc. @ 0.5% 0.50% 8495
of the material cost
Contingency Charges
3% 50972
@3%
Total Material Cost
1758557.
(Part -I)
Labour cost for
execution of the
scheme, overhead
charges including 14% 246198
Transportation,
Establishment &
Supervision charges for
 TYPICAL COST ESTIMATE FOR 1 KM 11KV UNDERGROUND XLPE CABLE (3CX300
SQ.MM. )
Sl.
Particulars Unit Qty. RATE Amount
No.
erection, testing &
commissioning Part (II)
Total Cost (Part I +Part
2004856
II) in Rs.
Total Cost Rs. in Lacs 20.05

Standard cost estimation report mentioned above shows that installation cost of 11 kV
Underground cable network is nearly 4 times the cost of installation of overhead network of
same voltage rating.
 References

1. CEA ( Technical Standards for construction of Electrical Plants and Electric Lines )
regulations 2010 as amended upto date

2. Main Indian standards ( as amended up to date)

IS 5613 Code of practice for design, installation and maintenance of overhead power lines
(Part 1/Sec 1) : 1985 Lines up to and including 11 kV. Section 1 Design (first revision)
(Part 2/Sec 1) : 1985 Lines above 11 kV and up to and including 220 kV, Section 1 design
(Part 2/Sec 2) : 1985 Lines above 11 kV and up to and including 220 kV, Section 2 installation
and maintenance
IS 9708 : 1980 Specification for stock bridge vibration dampers for overhead power lines
IS 10162 : 1982 Specification for spacers and spacer dampers for twin horizontal bundle
conductors
IS 12360 : 1988 Voltage bands for electrical Installations including preferred voltages and
frequency
IS:1554- PVC power cables.
IS:7098- XLPE power cables
IS:9968- Rubber based power cables
IS 3043 : 1987 Code or practice for earthing (first revision)
IS 14255/1995 : ABC cables upto 1100 volts.
IS 8130/1984 : Conductors for insulated cables.
IS 398/Pt.IV/1994: Aluminium alloy conductor.
IS 10418/1982 : Drums for electric cables
IS 1778 - Reels and drums of bare conductor.

IS: 1678, Specification for pre stressed concrete poles for overhead power, traction and
telecommunication lines
IS: 2905, Method of test for concrete poles for overhead power and telecommunications
lines.
IS: 7321, Code of Practice for selection, handling and erection of concrete poles for overhead
power and telecommunication lines